Simulation of micro-cutting considering finite deformation crystal plasticity

Micro-machining processes on metalic microstructures are influenced by the crystal structure, i. e. the grain orientation. Furthermore, the chip formation underlies large deformations. To perform finite element simulations of micro-cutting processes, a large deformation material model is necessary in order to model the hyperelastic and finite plastic material behaviour. In the case of cp-titanium material with hcp-crystal structure the anisotropic behaviour must be considered by an appropriate set of slip planes and slip directions. In the present work the impact of the grain orientation on the plastic deformation is demonstrated by means of finite element simulations of a finite deformation single slip crystal plasticity model. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

求解流固耦合问题的一种四步分裂有限元算法

基于arbitrary Lagrangian Eulerian (ALE) 有限元方法,发展了一种求解流固耦合问题的弱耦合算法．将半隐式四步分裂有限元格式推广至求解ALE描述下的Navier-Stokes（N-S）方程,并在动量方程中引入迎风流线（streamline upwind/Petrov-Galerkin, SUPG）稳定项以消除对流引发的速度场数值振荡;采用Newmark-β法对结构方程进行时间离散;运用经典的Galerkin有限元法求解修正的Laplace方程以实现网格更新,每个计算步施加网格总变形量防止结构长时间、大位移运动时的网格质量恶化．运用上述算法对弹性支撑刚性圆柱体的流致振动问题进行了数值模拟,计算结果与已有结果相吻合,初步验证了该算法的正确性和有效性．     

简单剪切有限塑性内时理论分析

在有限塑性内时理论中引入Jaumann率、广义Jaumann率、扶率及Wu率,并以此分析了简单剪切大变形问题．结果验证了简单剪切变形中,采用次弹性或内时刚塑性材料的Jaumann率客观模型,随单调递增的剪切变形剪切应力和法向应力都会出现振荡现象．这说明振荡现象的出现不取决于弹塑性模型,而与选取不同的客观率有很大的关系．同时指出在简单剪切大变形时,法向应力并不为零．     

p-version finite elements and finite cells for finite strain elastoplastic problems

In this paper, the p-version finite element method and its fictitious domain extension, the finite cell method, are extended to the finite strain J₂ plasticity. High-order shape functions are used for the finite element approximation of volume-preserving plastic dominated deformations. The accuracy and efficiency of p-version elements and cells in the finite plastic strain range are evaluated by the computation of two benchmark problems. It is shown that they provide locking free behavior and simplified meshing. These results are verified in comparison with the results of h-version elements in F-bar formulation. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Modelling Metals At Finite Deformation

During metal forming processes, substantial microstructural changes occur in the material due to large plastic deformations leading to different mechanical properties. It is of great interest to predict the behaviour of these materials at different fabriction stages and of the final product. At first glance, the behaviour of metals can be approached by an elastoplastic isotropic material model with a volumetric-deviatoric split and isotropic hardening. In order to perform the calculations, a logarithmic strain is considered in the principal directions of stress and strain space, allowing to make predictions even at finite deformations. Because of the actual nature of metals, the crystalline structure, the deformation at the microstructural level is much more complex. Due to the mathematically algorithmic form of an elastic predictor and a plastic corrector, the elastoplastic model can be extended to crystal plasticity which is similarly handled in terms of a critical resolved shear stress on defined slip planes in the crystal. Hardening can be modelled through a viscoplastic power law. (© 2010 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Kinematics of finite elastoplastic deformations

In this paper we review various approaches to the decomposition of total strains into elastic and nonelastic (plastic) components in the multiplicative representation of the deformation gradient tensor. We briefly describe the kinematics of finite deformations and arbitrary plastic flows. We show that products of principal values of distortion tensors for elastic and plastic deformations define principal values of the distortion tensor for total deformations. We describe two groups of methods for decomposing deformations and their rates into elastic and nonelastic components. The methods of the first group additively decompose specially built tensors defined in a common basis (initial, current, or “intermediate”). The second group implies a certain relation connecting tensors that describe elastic and plastic deformations. We adduce an example of constructing constitutive relations for elastoplastic continuums at large deformations from thermodynamic equations.     

Development of a single-layer finite element and a simplified finite element modeling approach for constrained layer damped structures

A new finite element (FE) is formulated based on an extension of previous FE models for studying constrained layer damping (CLD) in beams. Most existing CLD FE models are based on the assumption that the shear deformation in the core layer is the only source of damping in the structure. However, previous research has shown that other types of deformation in the core layer, such as deformations from longitudinal extension, and transverse compression, can also be important. In the finite element formulated here, shear, extension, and compression deformations are all included. As presented, there are 14 degrees of freedom in this element. However, this new element can be extended to cases in which the CLD structure has more than three layers. The numerical study shows that this finite element can be used to predict the dynamic characteristics accurately. However, there is a limitation when the core layer has a high stiffness, as the new element tends to predict loss factors and natural frequencies that are too high. As a result, this element can be accepted as a general computation model to study the CLD mechanism when the core layer is soft. Because the element includes all three types of damping, the computational cost can be very high for large scale models. Based on this consideration, a simplified finite modeling approach is presented. This approach is based on an existing experimental approach for extracting equivalent properties for a CLD structure. Numerical examples show that the use of these extracted properties with commercially available FE models can lead to sufficiently accurate results with a lower computational expense.     

ALTERING CONNECTIVITY WITH LARGE DEFORMATION MESH FOR LAGRANGIAN METHOD AND ITS APPLICATION IN MULTIPLE MATERIAL SIMULATION

A new approach for treating the mesh with Lagrangian scheme of finite volume method is presented. It has been proved that classical Lagrangian method is difficult to cope with large deformation in tracking material particles due to severe distortion of cells, and the changing connectivity of the mesh seems especially attractive for solving such issues. The mesh with large deformation based on computational geometry is optimized by using new method. This paper develops a processing system for arbitrary polygonal unstructured grid, the intelligent variable grid neighborhood technologies is utilized to improve the quality of mesh in calculation process, and arbitrary polygonal mesh is used in the Lagrangian finite volume scheme. The performance of the new method is demonstrated through series of numerical examples, and the simulation capability is efficiently presented in coping with the systems with large deformations.     

任意四边形杂交Mindlin板单元

本文把基于虚功原理的杂交有限元模型用于板弯曲问题，构造了一个考虑横向剪应变的任意四边形新型板单元，本单元的突出优点是采用了一种比较合理的位移插值函数，使之能较真实地模拟各类板的变形，且用的自由度最少。文中对此单元作了比较广泛的数值试验，计算结果表明它对板厚有相当宽的适用范围，对于各种例题均能在较粗的网格下得到满意的精度．     

A two-dimensional layerwise-differential quadrature static analysis of thick laminated composite circular arches

In this paper, a high accuracy and rapid convergence hybrid approach is developed for two-dimensional static analyses of circular arches with different boundary conditions. The method essentially consists of a layerwise technique in the thickness direction in conjunction with differential quadrature method (DQM) in the axial direction. Hence, the high accuracy and fast convergence of DQM with generality of layerwise formulations for modeling the transverse deformations of arbitrary laminated composite thick arches are combined. This results in superior accuracy with fewer degrees of freedom than conventional finite element method (FEM) or finite difference method (FDM). The convergence behavior of the method is shown and to verify its accuracy, the results are compared with those obtained based on the first order shear deformation Reissner–Naghdi type shell theory and also higher order shear deformation theory. The effects of opening angles, ply angle, boundary conditions, and thickness-to-length ratio on the stress and displacement components are studied.     

Elastoplastic deformation during projectile–wall collision

The Smoothed Particle Hydrodynamics method for elastic solid deformation is modified to include von Mises plasticity with linear isotropic hardening and is then used to investigate high speed collisions of elastic and elastoplastic bodies. The Lagrangian mesh-free nature of SPH makes is very well suited to these extreme deformation problems eliminating issues relating to poor element quality at high strains that limits finite element usage for these types of problems. It demonstrates excellent numerical stability at very high strains (of more than 200%). SPH can naturally track history dependent material properties such as the cumulative plastic strain and the degree of work hardening produced by its strain history. The high speed collisions modelled here demonstrate that the method can cope easily with collisions of multiple bodies and can also naturally resolve self-collisions of bodies undergoing high levels of plastic strain. The nature and the extent of the elastic and plastic deformation of a rectangular body impacting on an elastic wall and of an elastic projectile impacting on a thin elastic wall are investigated. The final plastically deformed shapes of the projectile and wall are compared for a range of material properties and the evolution of the maximum plastic strain throughout each collision and the coefficient of restitution are used to make quantitative comparisons. Both the elastoplastic projectile–elastic wall and the elastic projectile–elastoplastic wall type collisions have two distinct plastic flow regimes that create complex relationships between the yield stress and the responses of the solid bodies.     

Particle Finite Element Simulations of Cutting Processes in Manufacturing

The cutting of metals is an important process in manufacturing and challenges established methods in the field of computational mechanics. The particle finite element method (PFEM) combines the benefits of particle based methods and the standard finite element method (FEM) to account for large deformations and separation of material. In cutting simulations the workpiece is realised as a set of particles, whose boundary is detected by the α-shape method. After the boundary detection, the particles are meshed with finite elements. Since metals show a plastic behavior under large deformations, a suitable material model needs to be considered. Numerical examples show the effect of the choice of the parameter α on the cutting force. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Simulation and analysis of rotary forging a ring workpiece using finite element method

The methods of dealing with some key problems in analyzing a rotary forging process with a finite element method are given. The presented mechanical model of the finite element analysis is in accordance with the actual conditions of the rotary forging process. A three-dimensional rigid–plastic finite element analysis code is developed in FORTRAN language and used to analyze the rotary forging process of a ring workpiece. Velocity fields and stress–strain fields of both contact and non-contact zones of the ring workpiece in the rotary forging are obtained. The deformation mechanism and metal flow laws of the contact zone surface of the ring workpiece in the rotary forging process are revealed. The pressure distributions of the contact surface along the radial and tangential directions and effects of rotary forging parameters on deformation characteristics are given.     

On the h-adaptive coupling of FE and BE for viscoplastic and elasto-plastic interface problems

This paper presents a posteriori error estimates for the symmetric finite element and boundary element coupling for a nonlinear interface problem: A bounded body with a viscoplastic or plastic material behaviour is surrounded by an elastic body. The nonlinearity is treated by the finite element method while large parts of the linear elastic body are approximated using the boundary element method. Based on the a posteriori error estimates we derive an algorithm for the adaptive mesh refinement of the boundary elements and the finite elements. Its implementation is documented and numerical examples are included.     

有限变形问题拟主轴法*

所谓拟主轴标架,是一个单位正交标架,且相对于该标架的剪应变分量很小。作为Hill的主轴法的一种实用推广,我们在拟主轴杯架下建立了应变、转动、旋率、应变率、共轭应力和应力率在拟主轴标架下的近似表示形式。发展拟主轴法的目的,是试图既保留主轴法的主要优点,又可作为某种分析大变形问题的高效数值示析方法的基础。     

非线性尺规近似法在圆杆颈缩局部有限变形分析中的应用

形变局部化和不稳定的研究是当前力学问题的一个热点,其中最典型的问题是圆杆拉伸颈缩和滑移带的塑性分析。传统的微小变形弹塑性力学不能彻底解决此问题。本文采用以S(应变)-R(转动)分解定理为基础的非线性尺规数值计算法,并应用计算机模拟优化技术求出圆杆拉伸轴对称塑性有限变形的局部应变分布与发展形态。     

Adaptive FE analysis of plates by shear-flexible quadrilateral Reissner-Mindlin elements

h-version adaptive finite element analysis of plates using QUAD4 R-M elements is discussed. The necessity of using shear flexible formulations for plate elements in adaptive FEA is explained. Two shear flexible QUAD4 plate elements formulated by reconstituted shear strain fields are selected from literature and are used to solve both thin and thick plates with various geometries and boundary conditions. The effect of boundary layers in plates with soft or free boundaries is discussed and is shown in various examples. A powerful and versatile quadrilateral automatic mesh generator (MSD) is used for the discretization of the plate domain. The error norms are computed by the Z² as well as the superconvergence theory. The global convergence rates of the adaptive solutions with respect to the energy norms are demonstrated and it is seen that the theoretical rates of convergence are exceeded in several cases.     

Numerical analysis of shear bands in solids by means of computational homogenization

A novel fully three–dimensional framework for the numerical analysis of shear bands in solids undergoing large deformations is presented. The effect of micro shear bands on the macroscopic material response is computed by means of a homogenization strategy. More precisely, a strain–driven approach which complies well with displacement–driven finite element formulations is adopted. The proposed implementation is based on periodic boundary conditions for the micro–scale. Details about the implementation of the resulting constraints into a three–dimensional framework are discussed. The shear bands occurring at the micro–scale are modeled by a cohesive zone law, i.e., the tangential component of the traction vector governs the relative shear sliding displacement. This law is embedded into a Strong Discontinuity Approach (SDA). To account for realistic sliding modes, multiple shear bands are allowed to form and propagate in each finite element. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Analysis of laminated composite plates using higher-order shear deformation plate theory and node-based smoothed discrete shear gap method

This paper presents a novel finite element formulation for static, free vibration and buckling analyses of laminated composite plates. The idea relies on a combination of node-based smoothing discrete shear gap method with the higher-order shear deformation plate theory (HSDT) to give a so-called NS-DSG3 element. The higher-order shear deformation plate theory (HSDT) is introduced in the present method to remove the shear correction factors and improve the accuracy of transverse shear stresses. The formulation uses only linear approximations and its implementation into finite element programs is quite simple and efficient. The numerical examples demonstrated that the present element is free of shear locking and shows high reliability and accuracy compared to other published solutions in the literature.     

A geometrically nonlinear (3,2) reduced degree-of-freedom unified zigzag laminated beam element for large deformation analysis

A geometrically nonlinear (3,2) unified zigzag beam element is developed with a reduced number of degree-of-freedom for the large deformation analysis. The main merit of the beam element model is the Kirchhoff and Cauchy shear stress solution for large deformation and large strain analysis is more accurate. The geometrically nonlinearity is considered in the calculation of the zigzag coefficients. Thus, the results of shear Cauchy stress are matching well with solid element analysis in case of the beam with aspect ratio greater than 20 under large deformation. The zigzag coefficients are derived explicitly. The Green strain and the second Piola Kirchhoff stress are used. The second Piola Kirchhoff shear stress is continuous at the interface between adjacent layers priori. The bottom surface second Piola Kirchhoff shear stress condition is used to determine the zigzag coefficient and the top surface second Piola Kirchhoff shear stress condition is used to reduce one degree-of-freedom. The nonlinear finite element equations are derived. In the numerical tests, several benchmark problems with large deformation are solved to verify the accuracy. It is observed that the proposed beam has accurate solution for beam with aspect ratio greater than 20. The second Piola Kirchhoff and Cauchy shear stress accuracy is also good. A convergence study is also presented.